This procedure covers the removal and replacement of the front differential assembly on a 2012-2018 Jeep Wrangler JK with the 3.6L V6 engine and 4WD system.

Warnings

Tools required

Parts

• Front differential assembly × 1 — Use OEM specification
• Front axle nuts × 2 — Use OEM specification
• Differential cover gasket or RTV sealant × 1 — Mopar RTV or equivalent
• Differential mounting hardware (if damaged) × 1 — Use OEM specification

Fluids

• Mopar 75W-140 Synthetic Gear Lubricant — 1.5 qt

Preparation

1. Park vehicle on level surface and engage parking brake
2. Loosen front wheel lug nuts while vehicle is on ground
3. Raise front of vehicle and support securely on jack stands under frame rails
4. Remove both front wheels
5. Place drain pan under front differential

Procedure

1. 1

   Drain differential fluid
   Remove the differential cover bolts in a crisscross pattern, starting from the top. Allow the cover to remain partially attached at the top while fluid drains into the pan. Once drained, remove the cover completely and set aside. Clean the mating surface on the differential housing with a wire brush and razor scraper to remove old gasket material or RTV.
2. 2

   Remove front axle shafts
   Have an assistant apply brakes or use a pry bar to prevent hub rotation. Remove the 36mm front axle nuts from both sides and discard (new nuts required). These nuts may be staked and will require significant force to remove. Mark the orientation of each axle shaft for reference.
3. 3

   Disconnect CV joints from differential
   Remove the CV joint bolts connecting the inner CV joints to the differential output flanges on both sides. There are typically 6 bolts per side. Support the axle shafts with wire or bungee cords to prevent them from hanging on the outer CV joints and damaging the boots.
   Torque spec

   CV Joint Bolts71 Nm (52 lb-ft)
4. 4

   Mark and remove front driveshaft
   Use a paint marker or chalk to mark the relationship between the front driveshaft flange and the differential pinion flange to maintain balance. Remove the four driveshaft bolts at the differential end. Support the driveshaft and lower it away from the differential. Secure it out of the way with wire or rest it on the crossmember.
   Torque spec

   Driveshaft Bolts85 Nm (63 lb-ft)
5. 5

   Disconnect vent hose and breather
   Locate the differential breather vent hose on top of the differential housing. Disconnect the vent hose from the differential. Note the routing for reinstallation.
6. 6

   Support differential assembly
   Position a transmission jack or floor jack with a wide piece of wood under the differential housing to support its weight. Raise the jack until it just makes contact and slightly supports the differential weight, but do not lift the vehicle.
7. 7

   Remove differential mounting bolts
   Locate and remove all differential mounting bolts that secure the housing to the front axle assembly. There are typically 4 mounting bolts. Keep track of any washers or spacers. Carefully lower the differential assembly using the jack and remove it from under the vehicle.
   ⚠The differential assembly is heavy and awkward. Ensure the jack is stable and use a helper if available during removal.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
8. 8

   Prepare new differential
   Inspect the new or rebuilt differential assembly for any shipping plugs or protective covers. Verify that the correct gear ratio is specified for your vehicle (check door jamb sticker or build sheet). Clean the mounting surfaces and ensure all mounting points are free of debris.
9. 9

   Install differential assembly
   Using the transmission jack, carefully raise the new differential into position, aligning the mounting holes with the axle housing brackets. Install the mounting bolts and torque to specification in a crisscross pattern. Remove the jack once all bolts are secured.
   Torque spec

   Mounting Bolts31 Nm (23 lb-ft)
10. 10

    Reconnect vent hose
    Connect the differential breather vent hose to the fitting on top of the differential housing, ensuring it is routed properly and not kinked or pinched.
11. 11

    Install front driveshaft
    Align the marks made during removal on the driveshaft flange and differential pinion flange. Install the four driveshaft bolts and torque to specification in a crisscross pattern.
    Torque spec

    Driveshaft Bolts85 Nm (63 lb-ft)
12. 12

    Connect CV joints to differential
    Remove wire or bungee supports from axle shafts. Align the inner CV joints with the differential output flanges, matching the orientation noted during removal. Install the CV joint bolts and torque to specification in a crisscross pattern on each side.
    Torque spec

    CV Joint Bolts71 Nm (52 lb-ft)
13. 13

    Install differential cover
    Clean the differential cover and apply a continuous 3mm bead of RTV silicone gasket maker to the cover mating surface, circling all bolt holes on the inside. Install the cover and bolts, torquing in a crisscross pattern to specification. Allow RTV to cure per manufacturer instructions before filling with fluid (typically 1 hour).
    Torque spec

    Differential Cover Bolts39 Nm (29 lb-ft)
14. 14

    Fill differential with fluid
    After RTV has cured, remove the differential fill plug (typically on the side or front of the housing). Fill with Mopar 75W-140 Synthetic Gear Lubricant until fluid begins to drip from the fill hole (approximately 1.5 quarts). Install and tighten the fill plug.
15. 15

    Install axle nuts and stake
    Install NEW 36mm axle nuts on both front hubs. Torque to 281 Nm (207 lb-ft) using a breaker bar and torque wrench. After torquing, use a punch and hammer to stake the nut collar into the axle shaft groove, preventing the nut from loosening. Install wheels and torque lug nuts to specification in a star pattern.
    ⚠️Never reuse old axle nuts. The nut must be staked properly to prevent catastrophic failure during operation.
    Torque spec

    Axle Nut281 Nm (207 lb-ft)

    Wheel Lug Nuts156 Nm (115 lb-ft)

Reassembly

1. Ensure all fasteners are torqued to specification
2. Verify differential vent hose is properly routed and not kinked
3. Check that axle nuts are properly staked and secure
4. Confirm driveshaft alignment marks are matched to prevent vibration

Verification

• Lower vehicle and verify differential is secure with no leaks from the cover
• Start engine and shift transfer case through all ranges (2H, 4H, 4L) to verify engagement
• Test drive vehicle in 4WD on a suitable surface, listening for abnormal noises from the front differential
• After test drive, recheck differential fluid level at fill plug and top off if necessary
• Inspect for any fluid leaks around differential cover and all connection points
• After 50-100 miles, recheck all mounting bolts and axle nut stakes for security

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